Food Safety Management System Contents
Food Safety Management System Contents
Food Safety Management System Contents
The company has planned, established, documented and implemented a food safety and
quality management system for the site, which is maintained in order to continually
improve its effectiveness in accordance with legislation, international standards and best
industry practice. The company has planned and developed the processes that contribute
to meeting the requirements of these standards and producing safe products.
Scope
The scope of the Food Safety Management System includes all product categories,
processes and activities conducted on site and any outsourced activities. These
requirements are aligned with the policies and objectives of the site and include those of
the following standards:
Due diligence
The Food Safety Quality Manual demonstrates due diligence of the company in the
effective development and implementation of the food safety management system.
These documents are fully supported by the completion of the records specified in this
manual for the monitoring of planned activities, maintenance and verification of control
measures and by taking effective actions when non-conformity is encountered.
Food Safety
The company is committed to supplying safe products for consumption. As part of this
commitment, all products and processes used in the manufacture of food products are
subject to food safety hazard analysis based on the Codex Alimentarius guidelines to the
application of a HACCP system. All food safety hazards, that may reasonably be expected
to occur, are identified by this process and are then fully evaluated and controlled so that
our products do not represent a direct or indirect risk to the consumer. New information
regarding food safety hazards is continually reviewed by the Food Safety team to ensure
that the Food Safety and Quality Management system is continually updated and
Document Reference Food Safety Quality Management System
Revision 1 27th November 2011
Owned by: Technical Manager 5
Authorised By: General Manager
Food Safety Quality Management System
Finished Product Summary
HACCP Calculator ISO 22000
HACCP Definitions
HACCP Flow Diagram
HACCP Flowchart Verification
HACCP Flowcharts
HACCP Glass Control Verification Record
HACCP Hazards
HACCP Intended Use
HACCP Plan Sample
HACCP Prerequisites
HACCP Scope and Product Information
HACCP Steering Group Review
HACCP Team
The Prerequisite procedures of the Food Safety Quality Management System Procedures
are pre-fixed PRP and are as follows:
The controlled records of the Food Safety Management System are pre-fixed QMR and
are as follows:
The Prerequisite Records of the Food Safety Quality Management System Procedures are
pre-fixed PRPR and are as follows:
The Criteria and Methods required to ensure that the operation and control of these
processes are effective are documented in the Food Safety Management System
procedures and records.
These procedures are supported by second tier documents specific to each area
including:
- Work Instructions
- Specifications
- Testing schedules
- Risk assessments
- Job Descriptions
- Critical Control Point Monitoring Procedures
Measurement, monitoring and review are carried out by analysis of data in key areas
including:
Supporting Documents
and Records
Plan &
Document
Improve Implement
Maintain,
Review Measure,
Audit
It is company policy to operate a document and record control system within the scope
of the Food Safety Quality Management System and to meet the requirements of
international standards ISO 9001:2008 and ISO 22000:2005.
The food safety management system documentation includes the food safety policy and
food safety objectives, the procedures and records required by ISO 22000 and those
documents required to ensure the effective development, implementation and updating
of the
food safety management system.
All documents and records determined by the company to be necessary to ensure the
effective planning, operation and control of the processes are controlled within the food
safety management system.
The documentation which defines the Food Safety Quality Management System is
controlled. The company operates a system of document control for procedures and
standards which will enable the following activities:
The company operates a system of document control for records covered by the scope of
the Food Safety Management System.
Each record shall be given a unique reference code. The prefix letters of the code refer
to a particular kind of document, as shown below:
Records for the specific areas are sequentially numbered and a Master List for each area
is maintained by the Technical Manager.
All records are reviewed for adequacy before approval be authorised personnel.
Department Managers are responsible for the records used in their department.
Senior management demonstrate clear and visible commitment to the food safety
management system by establishing and implementing, then fully communicating and
supporting its policies, procedures and objectives. Senior Management is committed to
continually improve the effectiveness of the quality management system by regular
audit, review and pro-active actions.
The food Safety Management System includes all products manufactured on site and
activities conducted on site. The scope is aligned with the policies and objectives of the
site and includes the commitment to fully meet the requirements of the following
standards:
The Senior Management has a total commitment to quality observing all legal, moral and
ethical codes and this is the concern of every employee.
The following Crisis Team members have been trained in Crisis Management and are the
nominated first point of contact for the crisis situations described:
In all cases if the first point of contact cannot be contacted another member of the Crisis
Management Team must be contacted.
In real crisis situations a member of the Crisis Management Team must be contacted. The
person contacted will urgently contact and assemble the other members of the Crisis
Management Team. The Crisis Team will act quickly to assess the situation and formulate
an action plan which is communicated to the site management. All relevant aspects of
product safety, health and safety, financial effects and company image must be
considered prior to recommencing production. All crisis and action resulting from crisis
situations must be recorded.
If a call alleging or threatening extortion is received the person dealing with it should
attempt to transfer the call to a member of the Crisis Management Team if at all possible.
The company has established, documented and implemented procedures for purchasing
and verification of purchased materials, which are maintained in order to ensure all
purchased materials conform to agreed specifications in order that the quality and safety
of the end product is not compromised.
The scope of the procedures for purchasing and verification of purchased materials
includes all purchasing activities that have an impact on the Food Safety Quality
Management System
Initially suppliers are used because of their historic service record including Quality
Performance, Customer nomination or Price. This the starting point for an approved
supplier list. With the implementation of a controlled approved supplier list, suppliers
who do not reliably achieve specification are either delisted or if critical to the business,
are given technical support to become reliable. New suppliers are only added to
the list following successful sampling and technical approval. Customers can add a
nominated supplier to the list. This nomination may be overruled where product safety
could be jeopardised.
Materials and Services can only be purchased using the Approved Supplier List. Orders for
materials, chemicals, packaging and ingredients are raised and consignments of approved
materials are called off from approved suppliers against planned product order
requirements. All chemicals purchased for use within the food handling facility are
confirmed as “food grade” by the Technical Manager. The Planning Manager is
Document Reference Food Safety Quality Management System
Revision 1 27th November 2011
Owned by: Technical Manager 62
Authorised By: General Manager
Food Safety Quality Management System
industrial activities which pose a serious threat of contaminating food
Food facilities are located away from areas subject to flooding unless sufficient
4
safeguards are provided
5 Food facilities are located away from areas prone to infestations of pests
Food facilities are located away from areas where wastes, either solid or liquid,
6
cannot be removed effectively.
Periodic assessment of potential food safety impact from and to local
7
environment is performed
Design and layout
The internal design and layout of food buildings permits good food hygiene
1 practices, including protection against cross-contamination between and during
operations by foodstuffs.
2 There is always segregation of high and low risk areas.
There is restricted access to high risk areas and dedicated clothing, footwear,
3
tools and equipment.
4 Product Process flow is logical and follows a one way flow system
5 Process flow should be designed to prevent contamination
6 There are dedicated chill and freeze facilities where appropriate
7 There are segregated equipment washing facilities
The onsite laboratory is sited away from production areas or contracted out to
8
qualified laboratories
9 Facility is appropriate for the purpose
Adequate security arrangements are in place with restricted access on to site and
10
control of visitors
11 Site boundaries are clearly defined
12 Pest control of the periphery is in place
13 Operator/people movement is controlled to minimise risk of cross contamination
Buildings
All buildings are constructed to protect against the entrance and harbouring of
1
pests.
2 Entrances are heavily protected to prevent accidental damage
3 Pedestrian and Fork Truck access is separate
Foundations are at least 600mm deep and sufficient to prevent rodents from
4
burrowing underneath
Access points for pests is prevented by ensuring windows that open are
5
protected by insect screens
Operational PRP(s) are implemented across the entire production system as appropriate.
The following Operational PRP(s) have been implemented:
Decision Tree
Severity
Significance
Question 1
Question 2
Question 3
Question 4
Probability
Step Specific Details
Control
Num Step Name Hazards Identified about the
Measure
ber Hazard
Delivery of
1 Bone 3 3 9 N
Ingredient
Delivery of
1 Campylobacter spp. 3 3 9 Y N Y N
Ingredient
Delivery of Contamination with
1 3 3 9 Y N N
Ingredient Bacteria from pests
Delivery of
1 Pesticides 2 3 6
Ingredient
Delivery of Salmonella spp. (S.
1 2 2 4
Ingredient Typhimurium)
Delivery of Bacteria (spore-forming)
1 1 2 2
Ingredient General
Delivery of
1 Pest control chemicals 1 1 1
Ingredient
N = If control is required at this step for safety then modify step, process or product
The HACCP Calculator highlights significant hazards and critical control points in red.
Corrections
For each CCP and OPRP Corrections and Corrective actions when critical limits are
exceeded are defined by the Food Safety Team in the HACCP documentation and plans.
The HACCP team define and document the corrective action when trends indicate a likely
loss of control. Corrections are applied to bring the parameters controlled at the CCP or
OPRP under control and the correction instruction includes reporting requirements and
action to be taken by the authorised nominated person with regards to the products
produced while the process was out of control. Corrective Actions are defined to ensure
the cause of the breach is identified and action is taken to prevent a recurrence. Training
in monitoring procedures and records for CCP’s/OPRP’s and corrections/corrective
actions are completed ahead of implementation.
In the case of exceeding CCP/OPRP limits, procedures and records appropriate to the
handling of potentially unsafe products are followed until it is confirmed that they are
safe and suitable for release. Where product is not suitable for release then this matter is
reported as soon as practically possible to the Food Safety Representative. The Food
Safety Team carry out regular review of the corrections carried out.
Products manufactured under conditions where critical limits have been exceeded are
potentially unsafe products and are handled in accordance with the procedure for
controlling non-conforming products.
Corrective Action
Corrective Action is the action taken to eliminate the cause of an existing non-
conformance in order to prevent a recurrence. The procedure for corrective action is
managed by the Food Safety Representative (Technical Manager). This procedure defines
that when Non-Conformances are raised a corresponding agreed corrective action is
raised to eliminate the non-conformance and the cause of the non-conformance and that
action is taken to reduce the risk of or prevent a recurrence.
Customer complaints are analysed by product and type to identify complaint trends. The
annual complaint analyser tool generates longer term trend analysis. Complaint KPIs and
trends are reviewed at management review meetings.
Indications of Customer Satisfaction are provided from regular Review Meetings with the
Customer. This feedback is passed onto the Senior Management team by the Sales
Director. Feedback is also provided as a result of Customer Audits, these are usually
annually, the results of which are reported to the Senior Management team by the
Technical Manager. The Senior Management team consider the feedback at the
Management Review meetings and appropriate improvement plans are formulated.
Customer feedback is also evaluated and assessed during the Food Safety Team monthly
review.
Responsibilities
The Customer Services Manager and Quality Manager are responsible for responding
directly to Non-Critical customer complaints.
The Technical Manager is responsible for handling retailer and serious consumer
complaints.
The Food Safety Team is responsible for reviewing and assessing relevant customer
feedback to food safety and updating the Food Safety Quality Management system as
appropriate.
The Quality Manager is responsible for analysing performance trends, for agreeing
corrective and preventive action with site management and for updating the non
conformance register.
The Senior Management team are responsible for reviewing complaints trends and
implementing complaint performance improvement plans.